Cable connector system

ABSTRACT

A cable connector system is provided having a carrier strip and a center contact mounted to a conductive trace of a substrate, such as an automotive window glass, at a predetermined distance from the carrier strip to receive a stripped cable, such as a coaxial cable in order to provide for the quick and easy attachment of the cable to the substrate, such as for attachment of a cellular phone to an antenna on automotive window glass.

BACKGROUND OF THE INVENTION

This invention pertains to a cable connector system and, in particular,a connector for coaxial cables. The mounting of coaxial cable tosubstrates have been acomplished by many means such as coaxial connectorconnected to the cable and mounting the coaxial connector to a substrateor soldering the coaxial cable directly to a substrate. In certaincircumstance such as the attachment of coaxial cable to the rear windowof an automobile, in order to attach a telephone or radio to an antennain the window, a cable lead was soldered directly to the glass. However,such assembly leaves a flying lead where the cable is attached to theglass at one end and is free at the other end. During installation ofthe glass into the automobile, the flying lead gets in the way and, insome cases, may be used as a handle by assembly line workers to pick upthe glass. Such handling can cause damage to the connection of the cableto the glass. There is, therefore, desired a system which provides for alow cost, low profile connector for a substrate such as glass and allowsfor the later insertion and mounting of a cable within the connectorsystem after assembly of the substrate into its final position.

It is, therefore, an object of the present invention to provide for alow cost, low profile connector system which enables for the quick andeasy insertion of an electrical cable to provide for an electricalconnection.

It is a further object of the present invention to provide a connectorsystem which allows for the connection of a coaxial cable to a glasssubstrate quickly and inexpensively.

It is another object of the present invention to provide a connectorsystem which allows for the insertion of a cable therein and restrictsthe removal of the cable tereafter.

It is a further object of the present invention to provide a connectorsystem which is quickly and easily mountable to a substrate and quicklyand easily soldered thereto.

SUMMARY OF THE INVENTION

A principal object of this invention is to provide a connector systemcomprising a carrier strip having a generally U-shaped area and aretention strip mounted at the U-shaped area and a center contactmounted to a substrate a predetermined distance from the carrier strip,wherein a cable inserted through the carrier strip is received by thecenter contact. The carrier strip may include mounting tabs havingsolder adhered thereto for mounting the carrier strip to the substrate.The carrier strip and the center contact may be mounted to a housing.The substrate may be a window glass having an antenna embedded therein,attached to a trace which is connected to the carrier strip and thecenter contact. The retention strip may include a plurality of fingersbent around the edge of the U-shaped area of the carrier strip andprotruding within the U-shaped area of the carrier strip. The mountingtabs of the carrier strip may include offset dimples protrudingtherefrom.

In an embodiment, a cable connector is provided comprising a carrierstrip having a generally U-shaped area and mounting tabs adjacent theU-shaped area, solder attached to the mounting tabs and a retentionstrip mounted to the U-shaped area having retention fingers protrudingwithin the U-shaped area. The mounting tabs may include offset dimplesprotruding therefrom. The connector may be mounted to a conductive traceon a window glass. The carrier strip may be mounted to a housing whichis attached to a center contact.

A method of attaching a cable to a substrate is provided comprising thesteps of mounting a carrier strip having a U-shaped area and a retentionstrip attached at the U-shaped area to a conductive trace of thesubstrate, mounting a center contact to the conductive trace of thesubstrate, assembling the substrate to a finished piecework, andinserting the stripped end of a cable having an exposed conductor and acable shield bent back over the outer jacket of the cable through theU-shaped portion of the carrier strip and inserting the conductor withinthe center contact, wherein the cable is electrically connected to theconductive trace and grounded thereto. The carrier strip and the centercontact may be mounted in a housing prior to mounting to the substrateand wherein the carrier strip and the center contact are mounted to thesubstrate simultaneously. The connector assembly may provide for theelectrical connection of a coaxial cable to an antenna embedded in thewindow glass substrate which the carrier strip and the center contactare mounted to.

These and other features of the invention are set forth below in thefollowing detailed description of the presently preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of the present invention in its fullyassembled state;

FIG. 2 is a perspective view of the connector system of the presentinvention prior to insertion of the cable; and

FIG. 3 is a side partially cut-away view of an alternate embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

The invention is best understood with reference to FIGS. 1-3. FIG. 1discloses a substrate 10, for example, window glass for an automobile.The substrate includes conductive tracing on its outer surface 15 andincludes mounting points 16, 17. Prior to mounting of the substrate 10to the finished assembly such as at the rear of an automobile, a carrierstrip 20 is mounted at mounting point 17 to the substrate 10. Thecarrier strip includes a U-shaped area 21 and mounting tab 22. In apreferred embodiment, the carrier strip 20 is formed of a metallicmaterial such as tin/copper. Attached to the mounting, tab 22 is solder,such as solder preform 25. However, solder cladding may also be adheredto the mounting tab 22. The mounting tab 22 also has protruding from itan offset dimple 26. Also mounted at the U-shaped area 21 of the carrierstrip 20 is retention strip 28 having fingers 29 which are bent aroundand protrude into the interior of the U-shaped area 21. The retentionstrip 28 in a preferred embodiment is resistance-welded or riveted tothe carrier strip 20.

The carrier strip 20 is mounted to mounting point 17 by placing themounting tabs 22 parallel with the surface 15 of the substrate 10. Themounting point 17 includes a conductive trace which may be abraded andthe mounting tabs 22 mounted thereon and applying heat to the tabs 22.The solder 25 reflows and forms an electrical connection between thecarrier strip 20 and the mounting point 17 on the substrate 10. Theoffset dimple 26 of the mounting tab 22 provides for a space to beretained between the bottom of the mounting tab 22 and the surface 15 ofthe substrate 10. Therefore, applying pressure to the mounting tab 22will not force the solder 25 to be pushed out from out underneath themounting tab 22. In a preferred embodiment, a heating element is placeddown over the mounting tab 22 and puts pressure on the tab 22 in thedownward direction against the substrate 10. To avoid squeezing thesolder 25 out from underneath the mounting tab 22, the offset dimple 26retains an offset of the mounting tab 22 from the substrate 10 so thatsolder remains underneath the tab and a good electrical connection isachieved. In an alternate embodiment, a pair of offset dimples mayprotrude from each mounting tab 22. In a preferred embodiment thecarrier strip may be formed in a punch press to simultaneously form theU-shaped area 21, the, mounting tabs 22 and the offset dimple 26.

Spaced apart from the carrier strip 20 is center contact 30 which ismounted at mounting point 16 to the substrate 20. The center contact 30includes mounting wings 31, contact body 32 and outer sleeve 34. Thecontact body 32 is inserted through the length of the outer sleeve 34and forms two contact arms for receiving a conductor 41 of a cable 40.The mounting wings 31 of the center contact 30 have solder attachedthereto such as a solder cladding or solder preforms. The center contact30 is attached to the substrate 10 by heating of the solder and formingan electrical connection between the center contact 30 and the mountingpoint 16. The center contact 30 may be mounted to the substrate 10separately from or simultaneously with the carrier strip 20. The entireassembly (as shown in FIG. 2) may then be stored and transported forlater assembly to the finished piecework or automobile. It may beunderstood from the aforementioned description of the present inventionthat the finished substrate assembly does not have lengthy appendages orcables hanging therefrom or connectors which are obtrusive or difficultto attach. The center contact 30 and the carrier strip 20 provide for aquick and easy connector system which allow for a cable to be attachedto the substrate 10 in a quick and easy method at a later assemblystage.

In a preferred embodiment of the present invention, the substrate orwindow glass having the carrier strip 20 and the center contact 30mounted thereto is placed into the rear of an automobile body. The lowprofile carrier strip 20 and center contact 30 allow for themanipulation of the substrate 10 into the automobile body and do nothinder such assembly. Once the substrate or window glass 10 is mountedinto the automobile, a cable 40 may then be inserted into the connectorassembly of the present invention in order to connect an electronicapparatus such as a telephone to an antenna embedded into the windowglass 10. Prior to insertion of the cable 40 into the connector system,the cable is stripped, exposing the conductor 41 which is covered byinsulator 42. A cable shield 44 is also exposed and is folded back overthe outer jacket 46 of the cable 40. The cable is stripped to aparticular size so that the cable shield 44 is folded back at apredetermined distance from the exposed conductor 41 (see FIG. 3). Thecable is inserted through the U-shaped area 21 of the carrier strip 20.The cable 40 is inserted through the carrier strip 20 until it reachesits final mated position having the cable 44 shield centered within thecarrier strip 20 and the conductor 41 mated to the center contact 30.The fingers 29 of the retention strip 28 abut against the cable shield44 and help to retain the cable 40 within the carrier strip 20 andsimultaneously provide for grounding of the cable to the substrate 10.In a preferred embodiment, the retention strip 28 is made of a berylliumcopper which enhances grounding and electrostatic discharge.

The cable 40 in its final mated position provides for the conductor 41to be inserted within the center contact 30 within the outer sleeve 34to provide for an electrical connection to the substrate 10 at themounting point 16. Therefore, it may be appreciated that the presentconnector system provides for a quick and easy installation of a cableto the substrate and simultaneously provides for grounding of the cable.In a preferred embodiment, the cable 40 needs no further assembly and isretained within the connector assembly and attach to the substrate andallows for the cable to withstand a pull force of approximately one toten pounds without removal from the carrier strip 20 or center contact30. In an alternate embodiment, the cable may be secured more to thesubstrate 10 by use of solder or other mechanical means.

FIG. 2 is a perspective view of the connector system of the presentinvention prior to insertion of a cable. Substrate 10 includes trace 12adhered to the upper surface and providing for mounting points 16,17.The carrier strip 20 includes U-shaped area 21 and mounting tabs 22,23.Mounted on the U-shaped area 21 is retention strip 28 having a pluralityof fingers 29 bent over and protruding within the U-shaped area 21 ofthe carrier strip 20. Attached to the mounting tabs 22,23 are solderpreforms 25,27. Heat is applied to the mounting tabs 22,23 and thesolder 25,27 is reflowed providing for an electrical connection betweenthe carrier strip 20 and the conductive trace 17 of the substrate 10 sothat the cable may be grounded when inserted therein.

Center contact 30 is mounted to the substrate a predetermined distancefrom the carrier strip 20. The center contact 30 includes outer sleeve34, contact body 32 and mounting wings 31. Protruding within the outersleeve 34 are contact fingers 36,37 for receiving the conductor of acable. In a preferred embodiment, the contact body 32 and fingers 36,37are formed of a metallic material such as a beryllium copper and theouter sleeve 34 is formed of an insulating material such as a rubber orthermoplastic material. The outer sleeve 34 protects the contact fingers36,37 and also maintains the fingers in a prestressed position providingfor a normal force of the contact fingers 36,37 in order to provide apress-fit with a conductor of a cable.

FIG. 2 also discloses an alternate embodiment of the present inventionhaving a housing 50. The housing 50 provides for a means of holding thecarrier strip 20 and the center contact 30 together as a single unit. Inorder to aid in the quick assembly of the present connector system, thecarrier strip 20 and the center contact 30 may be mounted to the housing50 prior to installation to the substrate 10. The housing 50 may bepicked up and placed onto the substrate 10 providing for thesimultaneous placement of the carrier strip 20 and the center contact 30at their desired positions at mounting positions 16,17. The housing maybe designed so that is easily grasped by human fingers for placement orfor automated robotic pick and placement. The housing 50 also includes atapered interior 51 and a reduced diameter portion 52 which guides thecable to the opening of the center contact 30 and is easily insertedbetween the contact fingers 36,37. The housing 50 is attached to theU-shaped area 21 of the carrier strip 20 by any conventional means, suchas by chemical bonding or a mechanical clip. The housing 50 includes anopening at its end adjacent the reduced diameter portion 52 in order toreceive the center contact 30 which is attached thereto by anyconventional means such as chemical bonding or a mechanical clip. Thehousing 50 in a preferred embodiment is made of a nonconductive materialsuch as a thermoplastic. The housing 50 is formed so that it does notprotrude over the mounting tabs 22,23 so that they are exposed in theupwardly perpendicular direction so that a heating element may be placeddown over the carrier strip 20 without interference in order to solderthe carrier strip 20 to the substrate 10. Therefore, it may beunderstood that the present invention provides for a connector systemwhich allows for a cable, such as a coaxial cable, to be quickly andeasily installed to a substrate 10 such as window glass. Insertion ofthe cable through the U-shaped portion 21 of the carrier strip 20 andmating of the stripped conductor with the contact fingers 36,37 of thecenter contact 30 provides for electrical connection of the cable to thetrace 12. Simultaneously, the cable having the cable shield bent backover the outer jacket of the cable is grounded to the substrate throughthe retention strip 28 via fingers 29 abutting the cable shield.

FIG. 3 discloses a side partially cut-away view of an alternateembodiment of the present invention. The cable 40 is shown insertedwithin the carrier strip 20 which is partially cut away to expose thecable 40. In the alternative embodiment, a ferrule 60 has been placedover the cable shield 44 and crimped onto the cable 40. The ferrule mayhave ribs 61 or the crimping procedure of the ferrule 60 onto the cable40 may form the ribs 61. The ribs 61 are angled so that the cable 40 maybe easily inserted within the U-shaped area 21 of the carrier strip 20.Upon insertion of the cable 40, the ribs 61 of the ferrule 60 abutagainst the fingers 29 of the retention strip 28 mounted to the carrierstrip 20. It can thus be understood that the removal of the cable isinhibited by the plurality of fingers 29 abutting against the ribs 61 ofthe ferrule 60 which is crimped to the cable 40. In a preferredembodiment, the retention strip 28 may withstand a pull of force ofapproximately one to ten pounds. The ferrule 60, in a preferredembodiment, is formed of a metallic material such as tin-plated copperin order that the grounding of the cable 40 occur through the retentionstrip 28 and the carrier strip 20 to the substrate 10.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages. For example, it has beendescribed herein that the connector system of the present invention in apreferred embodiment is used for attachment of a coaxial cable to anantenna embedded in automotive window glass. However, the cableconnector system of the present invention may be used to connect anytype of cable to any type of substrate. It is, therefore, intended thatsuch changes and modifications be covered by the appended claims.

What is claimed is:
 1. A connector system comprising:a carrier striphaving a generally U-shaped area, mounting tabs having solder adheredthereto for mounting the carrier strip to the substrate and a retentionstrip mounted at the U-shaped area; and a center contact mounted to asubstrate a predetermined distance from the carrier strip wherein acable inserted through the carrier strip is received by the centercontact.
 2. The connector system of claim 1 wherein the carrier stripand the center contact are mounted to a housing.
 3. The connector systemof claim 1 wherein the substrate is a window glass having an antennaembedded therein, attached to a trace which is connected to the carrierstrip and the center contact.
 4. The connector system of claim 1 whereinthe retention strip includes a plurality of fingers bent around the edgeof the U-shaped area of the carrier strip and protruding within theU-shaped area of the carrier strip.
 5. The connector of claim 1 whereinthe mounting tabs of the carrier strip include offset dimples protrudingtherefrom.
 6. A cable connector comprising:a carrier strip having agenerally U-shaped area and mounting tabs adjacent the U-shaped area;solder attached to the mounting tabs for attaching the carrier strip toa substrate; and a retention strip mounted to the U-shaped area havingretention fingers protruding within the U-shaped area for retaining acable inserted within the U-shaped area of the carrier strip.
 7. Theconnector of claim 6 wherein the mounting tabs include offset dimplesprotruding therefrom.
 8. The connector of claim 7 wherein the connectoris mounted to a conductive trace on a window glass.
 9. The connector ofclaim 8 wherein the carrier strip is mounted to a housing which isattached to a center contact.
 10. A method of attaching a cable to asubstrate comprising the steps of:mounting a carrier strip having aU-shaped area and a retention strip attached at the U-shaped area to theconductive trace of the substrate; mounting a center contact to aconductive trace of the substrate; assembling the substrate to afinished piecework; inserting the stripped end of a cable having anexposed conductor and a cable shield bent back over the outer jacket ofthe cable through the U-shaped portion of the carrier strip andinserting the conductor within the center contact, wherein the cable iselectrically connected to the conductive trace and grounded thereto; andmounting the carrier strip and the center contact in a housing prior tomounting to the substrate and wherein the carrier strip and the centercontact are mounted to the substrate simultaneously.
 11. The method ofclaim 10 wherein a connector assembly provides for the electricalconnection of a coaxial cable to an antenna embedded in a window glasssubstrate which the carrier strip and the center contact are mounted to.12. The connector system of claim 1 wherein the predetermined distanceis determined in accordance with a functional frequency of the connectorsystem.